throbber
(19) United States
`(12) Patent Application Publication (10) Pub. No.: US 2013/0154543 A1
`(43) Pub. Date:
`Jun. 20, 2013
`Richards0n et al.
`
`US 2013 O154543A1
`
`(54)
`
`(71)
`
`(72)
`
`(21)
`(22)
`
`(63)
`
`METHOD AND APPARATUS FOR
`PROVIDING SUPPLEMENTAL POWERTO
`AN ENGINE
`
`Inventors:
`
`Applicants: Francis D. Richardson, Eudora, KS
`(US); Richard L. Henderson, Leawood,
`KS (US); John A. Fox, Eudora, KS
`(US); Russell W. Sherwood, Olathe, KS
`(US)
`Francis D. Richardson, Eudora, KS
`(US); Richard L. Henderson, Leawood,
`KS (US); John A. Fox, Eudora, KS
`(US); Russell W. Sherwood, Olathe, KS
`(US)
`Appl. No.: 13/768,534
`Filed:
`Feb. 15, 2013
`Related U.S. Application Data
`Continuation-in-part of application No. 12/436,562,
`filed on May 6, 2009, which is a continuation-in-part
`of application No. 12/330,875, filed on Dec. 9, 2008,
`now abandoned.
`
`(60) Provisional application No. 61/018,715, filed on Jan.
`3, 2008.
`
`Publication Classification
`
`(51) Int. Cl.
`H02. 7/00
`(52) U.S. Cl.
`CPC ...................................... H02J 7/007 (2013.01)
`USPC ............ 320/104; 320/136; 320/134; 320/109
`
`(2006.01)
`
`(57)
`ABSTRACT
`A method and apparatus provides Supplemental power to an
`engine. The method and apparatus includes a pair of conduc
`tive leads for connecting the Supplemental power to an engine
`electrical system, one or more batteries connected in parallel
`with one or more capacitors, a relay connected to the conduc
`tive leads, a shunt cable connecting the batteries and capaci
`tors to the relay and a processor for controlling the relay to
`selectively apply electrical power to the engine electrical
`system. The method and apparatus includes safety features to
`reduce the risk of injury to the operator and damage to the
`apparatus and/or engine electrical system.
`
`
`
`Sgs
`
`M780s
`
`5W
`
`GND
`to 30
`
`r
`310
`
`NAS8NA
`
`3 -1
`
`9.9K
`
`1
`
`NOP
`
`NOCO Ex. 1004
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`

`

`Patent Application Publication
`
`Jun. 20, 2013 Sheet 1 of 12
`
`US 2013/O154543 A1
`
`- 10
`
`- 12
`
`- 16
`- 46
`
`HControl & Data—D
`
`Backlit LCD
`Display
`
`-2O
`
`HO:
`24
`
`- 48
`-50
`
`Reverse Voltage LED
`
`AUTOMOde LED
`
`- 52
`MANUAL Mode LED
`- 54
`-56
`
`Charge Battery LED
`
`FAULTLED
`
`- 70
`
`-72
`
`Annunciator
`
`Keypad
`
`
`
`
`
`
`
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`
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`
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`
`
`
`
`
`
`
`
`
`
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`
`
`
`14 N
`
`Battery Voltage
`Sensor
`
`Reverse Voltage
`SensOr
`
`Vehicle Voltage
`SensOr
`
`Solenoid Voltage
`Sensor
`
`32
`—
`- 38
`H
`
`40
`System
`Microcontroller
`Ho
`
`42
`
`Battery
`Temperature
`Sensor
`shunt Cable
`Temperature
`Sensor
`AUTOMATIc ?
`Mode PushButton
`
`MANUAL MOde
`PushButton
`
`- 44
`
`H)
`
`Shunt Cable
`Current Sensor
`
`Capacitor
`Temperature
`SensOr
`
`Capacitor Woltage
`SensOr
`
`- 47
`
`- 49
`
`D
`
`Sensor Wiring Harness
`
`Jump Starter
`Batteries
`Jump Starter
`Capacitors
`
`21
`
`59
`
`22
`
`OOAWG Cable
`
`
`
`34 N
`
`
`
`Contact Relay
`
`26
`
`Sensor Wiring Harness
`
`
`
`Vehicle to Be
`Started
`
`Fig. 1
`
`NOCO Ex. 1004
`Page 2
`
`

`

`Patent Application Publication
`
`Jun. 20, 2013 Sheet 2 of 12
`
`US 2013/O154543 A1
`
`
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`
`NOCO Ex. 1004
`Page 3
`
`

`

`Patent Application Publication
`
`Jun. 20, 2013 Sheet 3 of 12
`
`US 2013/O154543 A1
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`NOCO Ex. 1004
`Page 4
`
`

`

`Patent Application Publication
`
`Jun. 20, 2013 Sheet 4 of 12
`
`US 2013/O154543 A1
`
`26
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`35 34
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`1-52
`
`NOCO Ex. 1004
`Page 5
`
`

`

`Patent Application Publication
`
`Jun. 20, 2013 Sheet 5 of 12
`
`US 2013/O154543 A1
`
`12
`
`
`
`
`
`3.
`
`ai Y
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`
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`Fig. 2D
`
`NOCO Ex. 1004
`Page 6
`
`

`

`Patent Application Publication
`
`Jun. 20, 2013 Sheet 6 of 12
`
`US 2013/O154543 A1
`
`/1 2O8
`
`Call System
`Self-Test
`
`4O2
`
`/
`
`/ Display Error
`8.
`/
`Message &
`- Yes D
`Fault
`Detected? -
`V Service phone !
`Y. Number
`/
`
`Initialize MCUHW
`Declare Functions
`Declare Global Wariable
`Initialize ISRs
`
`Restore History
`Parameters from
`EEPROM
`
`2O4
`
`2O6
`
`
`
`
`
`Display Start
`Screens
`
`No
`
`21 O
`
`-
`
`A
`-
`Main Process 8
`LOOp
`
`&
`
`Check Flags
`
`-Display - 228
`y
`Battery
`\
`Charging
`Yes
`(
`\ Message &
`N LED
`
`/
`
`- 212
`- Battery N
`- ×
`Charging
`>
`N Voltage? -
`&
`
`Y.
`
`^
`
`-
`
`-
`
`y - 230
`- Charging
`a
`Complete? -
`
`214 N
`- Reversed
`KJumper Cable >
`Voltage? -
`
`-
`
`NO
`
`No
`
`Fig. 3
`
`Increment
`Reversed Voltage
`Error Count
`
`
`
`- 218
`rDisplay
`Reversed
`Voltage Error K
`y
`Message &
`Y.
`LED
`A
`22O -Ny \
`
`No
`
`-
`Error Y
`N. Corrected? -
`
`NOCO Ex. 1004
`Page 7
`
`

`

`Patent Application Publication
`
`Jun. 20, 2013 Sheet 7 of 12
`
`US 2013/O154543 A1
`
`- Shunt's
`K Calibration D
`NFlag Set? -
`
`No
`Y - 42O
`-Upload Data to >
`PC Flag Set? -
`
`
`
`428
`
`Copy Variables to
`Output Buffer
`
`Yes
`
`Set Output Buffer
`Ready Flag
`
`-426
`
`Clear Upload Data
`Flag
`
`Toggle Remote Control
`Status Flag:
`If True, Unit Can Be
`Controlled By PC or Local
`Buttons
`lf False, Unit Can Only Be
`Controlled by Local Buttons
`
`4 -408
`
`Yes
`
`CIOSe Starter
`Contact Relay
`
`V -410
`
`Measure Shunt
`Cable
`Temperature
`
`V - 412
`Read Woltage
`Drop Across Shunt
`Cable
`
`-414
`
`Measure Shunt
`Cable
`Temperature
`Again & Calculate
`Average Temp
`V -416
`
`Calculate & Save
`Shunt Resistance
`
`V - 418
`
`Clear Shunt
`Calibration Flag
`
`43O
`
`/1
`Copy Data From
`Input Buffer to
`Variables
`
`7-432
`
`Download Data
`D{ from PC Flag -Yes-D
`N Set? -
`-436
`y - 434
`- PC Remote
`Clear Download
`Yes- Control Flag D-CH
`Data Flag
`N.
`Set? -
`
`Fig. 4
`
`NOCO Ex. 1004
`Page 8
`
`

`

`Patent Application Publication
`
`Jun. 20, 2013 Sheet 8 of 12
`
`US 2013/O154543 A1
`
`222
`
`-22
`4
`
`- Low Battery
`Voltage?
`
`W
`
`-
`
`Yes
`
`Increment Charge
`Battery Error
`Count
`
`|
`
`^
`
`Y.
`
`
`
`'-225
`ADisplay Charge t
`/ Battery Error
`- 5.5"
`Ys LED
`- -->
`y Charging
`Voltage
`Detected? -
`-
`-
`
`w
`
`8
`

`<
`
`No
`
`|
`
`No
`v - 232
`- N.
`High
`s Bip -
`P
`r
`N
`O
`y / 239
`- (
`24 1.
`- High Y.
`Y.
`{ Capacitor >
`NVoltage? - Yes
`--
`|
`
`243
`r
`-Display N
`Increment
`? Capacitor
`Capacitor Voltage D. Over Voltage
`High Error Count | \, Message &
`LED
`
`|
`|
`
`/
`242
`
`/1
`E.
`Overheat Error
`Count
`
`234
`
`Yes
`
`Yx - 236
`
`--.
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`^
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`%
`& Overheat Error
`8,
`Y. Message & /
`LED
`
`1 238
`- Batt/Cap's
`D.
`Temp <
`NThreshold? -
`Y
`-
`^^
`
`No
`
`Yes
`
`No
`
`No
`
`- \s - 240
`- st
`-High Shunt Cables
`Y s Temperature? - --
`
`Increment Shunt -
`Cable Overheat
`Error Count
`
`?
`
`-
`'t
`/ Display System
`Ready
`v
`Message
`\s
`-
`---
`A Display
`{
`Incorrect
`y
`Voltage
`Message
`
`Yes
`
`254
`
`-248
`-250
`- si?
`- MANUAL or AUTO.
`No
`P.
`so
`us-
`is -
`r
`Yes
`y 7- 252
`vehicle's
`'
`<-No- Volts win Correct >
`|
`Range? --
`is
`/
`s
`-
`
`No
`
`- 244
`/Display Shunt t
`A Cable Overheat
`8, Error Message &
`
`Y-
`
`/
`LED
`^
`y - 246
`(
`u-Shunt Cables
`< Temperature Below >
`'s Threshold? -
`su
`
`Yes
`
`- 256
`Nf
`-
`- Correct Voltage
`- Selected? --
`
`Y.
`
`-
`
`No
`
`Fig. 5
`
`NOCO Ex. 1004
`Page 9
`
`

`

`Patent Application Publication
`
`Jun. 20, 2013 Sheet 9 of 12
`
`US 2013/O154543 A1
`
`-260
`Display AUTO \
`/ Mode Seconds K
`Auto
`TimeOut
`\
`w
`f
`Countdown
`s
`
`A?
`
`/ 2 62
`
`Onitor Wehicle
`Ho vs. f Ster
`Engagement
`
`Yes
`- 264
`- Vehicle Y.
`< Equipment )
`Voltage Drop?
`-
`^^
`
`No
`
`No
`
`y - 265
`-
`-\s
`-AUTO Mode
`Timeout )
`Expired? -
`\
`-
`Y-
`
`k
`
`No
`v
`-- - 2 6 7
`AUTO Button
`— Pushed to >
`Y Cancel -
`s
`-
`
`r 332
`- 258
`r:
`/
`- Manual N.
`Display
`{ or Automatic >-Manual-)
`s
`-
`\ MANUAL Mode
`j
`Mode? -
`x
`-
`-
`N
`a
`Yu-
`--
`
`/
`
`- MANUALN
`Button
`X
`Y.
`-
`- Pushed?
`N
`N.
`Y-
`334
`
`No
`
`Yes
`
`- s - 266
`-
`- Total Start
`N
`> Attempts > Allowed per )
`Time Limit? -
`Y-
`--
`> -
`
`--
`
`336
`
`/
`Increment Over
`Yes—D Start Attempt Error
`Count
`
`338
`
`Y.
`/ Display Cool 3
`(
`Down Wait
`\
`Message
`N
`
`/
`
`Y - 340
`/
`-
`N
`( Five Minutes? >
`-
`Y.
`-
`
`Yes
`v
`
`No
`
`NO
`
`Yes
`
`v
`-->
`f — *
`
`Yes
`
`V
`Close Starter
`Contact Relay &
`Start Relay On | |
`Time
`
`Increment Start
`Cycle Count
`
`N 27O
`
`\
`Display
`/
`8
`Starting
`\ Current & Auto |
`LED On /
`
`Fig. 6
`
`NOCO Ex. 1004
`Page 10
`
`

`

`Patent Application Publication
`
`Jun. 20, 2013 Sheet 10 of 12
`
`US 2013/O154543 A1
`
`y
`- Y, 7- 274
`Bater Tem >
`{ ELE >
`Yes
`N
`-
`
`^
`
`No
`
`-280
`
`D
`
`Increment Battery
`Temp
`Error Count
`
`
`
`
`
`
`
`Open Contact
`Relay & Turn on
`FAULTLED
`
`/1 282
`
`- Y. X
`Cable Temp>
`\
`Max Limit? >
`-
`
`^
`
`<
`
`Increment Cable
`Yes—D
`Temp
`Error Count
`
`r
`No
`v - 284
`-caren t increasing
`C Geometrical '9)
`Yes
`s
`y
`r
`
`/1
`Increment Current
`> Doubling Error
`Count
`
`286
`
`288
`
`/
`/Display Battery y
`Explosion
`>
`\ Message
`^x --
`
`a
`
`Open Contact
`D Relay & Turn on
`FAULTLED
`
`29O
`
`292
`
`-
`Ys
`AUTO Button
`N Pushed? -
`
`Y.
`
`-
`
`No
`
`No
`
`y 7- 294Yes
`\
`1.
`- Five Minutes
`-
`Expired?
`
`Yes
`
`No -296
`
`O
`
`^
`-
`Increment Open
`- AUTO Mode 8
`Zero On Yes P. Circuit Error Count
`s
`^
`Y -
`-304
`
`- 298 --- - 3OO
`/ .
`w
`/ Display Open
`HA
`Circuit
`y Error Message
`N
`-306
`Display
`\
`A Jumper Cable
`Unplugged
`V
`NError Message /
`
`?
`
`A
`
`Increment Jumper
`Yes D. Cable Unplugged
`Error Count
`
`-
`Jumper Cables
`Unplugged? -
`Y.
`- r
`-308
`
`- 31 O --- - 312
`/ Display Over \
`Current > Max
`Increment Over
`a'
`Maximum
`( Limit for 500 D-Yes->MAX Current Error
`H
`Count
`Starting Current
`ms? -
`NError Message /
`
`-
`
`y
`
`No
`
`-314
`- 316 - 318
`/ Display Over y
`- Start Current>>
`Increment Over
`/
`High Starting H
`- High Current for 15 O-Yes). High Current Error
`Ho
`Count
`y
`Current
`N Seconds? -
`YError Message /
`\
`^
`
`---
`
`x
`
`w
`
`s
`
`w
`
`No
`
`Fig. 7
`
`NOCO Ex. 1004
`Page 11
`
`

`

`Patent Application Publication
`
`Jun. 20, 2013 Sheet 11 of 12
`
`US 2013/O154543 A1
`
`- 7- 32O
`^ Shunt Resistors
`Open Circuit? -
`
`/ Display Current X
`Increase Current
`H> Shunt Failure
`H
`Yes—0.
`Shunt Error Count
`y Error Message f
`
`7- 322
`
`328 7
`
`- Contact Relay
`-
`Failure? -
`
`Increase Contact
`Relay Failure
`Count
`
`w
`
`Error Message
`

`
`No
`
`34-2
`
`AUTO Mode 8
`- Starting Current
`\ Decrease Below /
`Y Threshold? /
`
`N
`
`N
`
`-
`
`*
`
`348
`
`v A N.
`MANUAL Mode
`- & AC Start Current
`/
`Profile
`Completed? /
`
`N
`
`Yes
`
`Yes
`
`Open Contact
`Relay & Turn on
`FAULTLED
`
`-344
`A Display Start
`f
`Cycle
`...
`Complete
`Message
`
`/
`
`---
`
`Open Contact
`Relay
`
`- 292
`- AUTO Button
`Pushed?
`
`35O
`
`/ -
`- Contact Relays
`On > Maximum ^
`NAIlowed Time?-
`\
`-
`^.
`
`Yes
`
`/ Display
`?
`Maximum
`> Starter On
`&
`Message
`s-
`
`\
`s
`
`8
`/
`-
`
`NO
`y
`- AUTO Buttons
`Pressed? -
`
`4
`
`-356
`
`/ Display Start \
`Yes—) Cycle Halted
`N Message
`|
`
`
`
`Timeout? - ^
`
`Yes
`
`No
`
`Fig. 8
`
`NOCO Ex. 1004
`Page 12
`
`

`

`Patent Application Publication
`
`Jun. 20, 2013 Sheet 12 of 12
`
`US 2013/O154543 A1
`
`SRY 5OO
`Entry,
`/ 5O2
`
`Timer Based
`Interrupt
`Called Every 25
`S
`
`- Serial Input -504
`
`-
`s
`K Buffer Flag )—A-No
`Y.
`Set? -
`
`D
`
`Yes
`
`/ 5O6
`Read Configuration Byte &
`Set/Clear Operation Flags.
`PC Remote Control,
`Shunt Calibration,
`Parameter Download,
`Parameter Upload
`Clear input Buffer Flag
`
`No
`
`-
`
`-508
`- Serial Output
`< Buffer Flag )—
`Y.
`Set? -
`
`51O
`
`Transmit Serial
`Output Buffer to
`PC & Clear Output
`Buffer Flag
`
`Fig. 9
`
`512
`
`/1
`Read All Input Parameters:
`Battery Voltage
`Vehicle Voltage
`Solenoid Voltage
`Battery Temperature
`Starting Current
`Current Shunt Temperature
`Read Current Switch Inputs
`
`
`
`Calculate 16-Point
`Moving Average of
`All Parameters
`
`v -516
`1.
`-PC Remote
`Control Flag )
`Yes—b
`^
`Set? -
`
`7-518
`1
`
`Copy All Input
`Parameters &
`Status to Output
`Buffer
`
`No
`
`V - 520
`Set Output Buffer
`Flag
`
`522
`Calculate Manual
`Mode AC Starting 7
`Current Profile
`y
`
`Increment All
`Event Timer
`Counts
`
`Monitor AUTO & 7- 52 6
`MANUAL Mode
`Input Buttons &
`Set Oni Coff Status
`for Each
`
`(Exit Y
`ISR
`
`NOCO Ex. 1004
`Page 13
`
`

`

`US 2013/0154543 A1
`
`Jun. 20, 2013
`
`METHOD AND APPARATUS FOR
`PROVIDING SUPPLEMENTAL POWERTO
`AN ENGINE
`
`CROSS REFERENCE TO RELATED
`APPLICATIONS
`0001. This application is a continuation-in-part of appli
`cation Ser. No. 12/436,562, filed May 6, 2009, entitled
`METHOD AND APPARATUS FOR PROVIDING
`SUPPLEMENTAL POWER TO AN ENGINE, which is a
`continuation-in-part of application Ser. No. 12/330,875, filed
`Dec. 9, 2008, entitled METHOD AND APPARATUS FOR
`PROVIDING SUPPLEMENTAL POWERTO AN ENGINE,
`which claims the benefit of provisional patent application
`61/018,715, filed Jan. 3, 2008. with the same title.
`
`FIELD
`0002 The present invention relates to a portable power
`Source for a motor vehicle and, more particularly, to a method
`and apparatus to provide Supplemental power to start internal
`combustion and turbine engines.
`
`BACKGROUND
`0003 Internal combustion and turbine engines require a
`power source to start. Commonly, this power source is in the
`form of a battery, which provides power to a starter motor,
`which in turn drives the engine. The crankshaft of the engine
`is rotated by the starter motor at a speed sufficient to start the
`engine. If the battery goes dead or otherwise lacks sufficient
`power for the starter motor to drive the engine, the engine
`won't start. Environmental factors, such as temperature,
`affect the output of the battery and power required to rotate
`the engine.
`0004 If the battery lacks sufficient power to start the
`engine, a Supplemental power source is necessary to jump
`start the engine. Typically, jumper cables are used to connect
`the battery of one vehicle to the dead battery of another
`vehicle needing to be jumped. The batteries are connected in
`parallel using heavy cables (jumper cables) which are con
`nected to the terminals of the batteries using conductive
`clamps.
`0005. Several potential problems arise from the use of
`conventional jumper cables. Batteries in motor vehicles are
`capable of producing from 2,500 to more than 45,000 watts of
`power. If the batteries are cross-connected or the clamps
`inadvertently contact each other when one end of the jumper
`cables is connected to a battery, sparking can occur resulting
`in damage to the battery, the electrical system of the vehicle,
`and injury to the user of the jumper cables. If the jumper
`cables are not properly connected, there is a potential for the
`batteries exploding and fire, which may result in injury to
`those in proximity to the vehicle being jumped. Furthermore,
`the user is not given any indication as to the reason the battery
`is dead, which may only cause additional problems when
`trying to jump start the dead battery.
`
`SUMMARY
`0006. The present invention provides an apparatus and
`method for temporarily delivering Supplemental power to the
`electrical system of a vehicle. The apparatus and method
`performs real-time monitoring of all system parameters to
`increase the safety and effectiveness of the units operation
`
`while providing additional parametric and diagnostic infor
`mation obtained before, during and after the vehicle starting
`operation.
`0007. The present invention monitors the voltage of the
`battery of the vehicle to be jump started and the current
`delivered by the jump starter batteries and capacitors to deter
`mine if a proper connection has been established and to pro
`vide fault monitoring. For safety purposes, only if the proper
`polarity is detected can the system operate. The Voltage is
`monitored to determine open circuit, disconnected conduc
`tive clamps, shunt cable fault, and Solenoid fault conditions.
`The current through the shunt cable is monitored to determine
`if there is a battery explosion risk, and for excessive current
`conditions presenting an overheating condition, which may
`result in fire. The system includes one or more internal bat
`teries and capacitors to provide the power to the battery of the
`vehicle to be jump started. Once the vehicle is started, the
`vehicle's electrical system may recharge the batteries and
`capacitors before the unit automatically electrically discon
`nects from the vehicle's battery.
`
`BRIEF DESCRIPTION OF THE DRAWINGS
`0008 FIG. 1 is a functional block diagram of the portable
`power source of the present invention.
`0009 FIG. 2 (divided into FIGS. 2A, 2B, 2C and 2D) is a
`schematic of the portable power source, control circuit and
`sensors of the present invention.
`0010 FIGS. 3-8 are flow charts of the processing steps of
`the portable power source of the present invention.
`(0011 FIG.9 is a flow chart of the interrupt service routine
`of the system of the portable power source of the present
`invention.
`
`DESCRIPTION
`0012. As required, detailed embodiments of the present
`invention are disclosed herein. However, it is to be understood
`that the disclosed embodiments are merely exemplary of the
`invention that may be embodied in various and alternative
`forms. The figures are not necessarily to Scale; some features
`may be exaggerated or minimized to show details of particu
`lar components. Therefore, specific structural and functional
`details disclosed herein are not to be interpreted as limiting,
`but merely as a representative basis for the claims and/or as a
`representative basis for teaching one skilled in the art to
`variously employ the present invention.
`0013 Moreover, except where otherwise expressly indi
`cated, all numerical quantities in this description and in the
`claims are to be understood as modified by the word “about
`in describing the broader scope of this invention. Practice
`within the numerical limits stated is generally preferred. Also,
`unless expressly stated to the contrary, the description of a
`group or class of materials as Suitable or preferred for a given
`purpose in connection with the invention implies that mix
`tures or combinations of any two or more members of the
`group or class may be equally suitable or preferred.
`0014 Referring initially to FIG. 1, the portable supple
`mental power source (jump starter) of the present invention is
`generally indicated by reference numeral 10. Jump starter 10
`includes a programmable microprocessor 12 which receives
`inputs 14 and produces informational outputs 16 and control
`outputs 18. Microprocessor 12 provides flexibility to the sys
`tem 10 to allow updates to the functionality and system
`parameters without changing the hardware. In the preferred
`
`NOCO Ex. 1004
`Page 14
`
`

`

`US 2013/0154543 A1
`
`Jun. 20, 2013
`
`embodiment, an 8-bit microprocessor with 64 k bytes of
`programmable flash memory is used to control the system 10.
`One such microprocessor is the ATmegaé44P available from
`Atmel Corporation. The microprocessor 12 may be pro
`grammed via an internal connector 90, or an external connec
`tor 92 (see FIG. 2). It should be understood that other pro
`gramming ports may be included are not limited to the two
`shown in the figure.
`0015. A capacitor voltage sensor 49 monitors the voltage
`level of one or more capacitor 21. The capacitors 21 may
`include energy storage modules containing six or more ultra
`capacitor cells, for example. The capacitor modules 21 may
`be connected in series to obtain higher operating Voltages or
`in parallel to provide additional energy storage. One Such
`capacitor module is the Boostcap Energy Storage Module
`available from Maxwell Technologies, Inc.
`0016. A battery voltage sensor 20 monitors the voltage
`level of one or more jump starter batteries 22. A reverse
`Voltage sensor 24 monitors the polarity of the jumper cables
`on line 26 which are connected to the vehicle's electrical
`system 28. A vehicle voltage sensor 30 monitors the voltage
`on line 37 (voltage of the vehicle). When the contacts are
`open, the Solenoid Voltage sensor 32 input to microprocessor
`12 is used to measure the Voltage of the jump starter capaci
`tors 21 and batteries 22, which may be configured for various
`jump starter Voltages. When the contacts are closed, the Volt
`age difference between the capacitors 21 and batteries 22, and
`the contact relay 34 is used to measure the Voltage drop across
`a temperature-and-resistance calibrated 00 AWG shunt cable
`36 in order to calculate the current being delivered by the
`jump starter capacitors 21 and batteries 22 to the vehicle's
`electrical system 28. Although the present invention is dis
`closed and described as temporarily connected to a vehicle, it
`should be understood that it is equally applicable to a station
`ary engine. Additionally, the connection method to the elec
`trical system or batteries of the engine to be started is not
`important and may include conductive clamps, NATO con
`nectors, or may be permanently hardwired to the system, for
`example.
`0017. A battery temperature sensor 38 monitors the tem
`perature of the jump starter's batteries 22 to detect overheat
`ing due to excess current draw from the batteries during jump
`starting. A shunt cable temperature sensor 40 monitors the
`temperature of the 00 AWG shunt cable 36 in order to com
`pensate for resistance changes of the shunt cable due to the
`high current passing through the shunt cable 36 and to detect
`overheating conditions. The unit 10 also includes automatic
`42 and manual 44 pushbutton inputs to accept user input to
`select either automatic or manual operation.
`0018. The temperature of 00 AWG shunt cable 37 may
`also be monitored by a temperature sensor or thermal switch
`41. As long as the temperature of the cable 37 is below a
`predetermined limit, the input on line 58 is passed through
`sensor 41 to line 59 to enable the contact relay 34 as con
`trolled by system microcontroller 12. If the temperature of the
`cable 37 exceeds a predetermined limit, then the temperature
`sensor 41 presents an open circuit to control line 58 to disable
`contact relay 34 and not allow power to be applied to the
`vehicle 28. It should be understood that the temperature sen
`sor 41 may be coupled to cable 36, 37 or any other cable that
`may become overheated. Additional temperature sensors may
`be used to provide additional protection of the system from
`overheating.
`
`0019. A capacitor temperature sensor 47 monitors the
`temperature of the jump starter capacitors 21 to detect over
`heating due to excess current draw from the capacitors during
`jump starting.
`0020. The microprocessor 12 includes several outputs 16
`to provide information to the user and to control the applica
`tion of power to the vehicle to be jump started. An LCD
`display 46 may be used to display user instructions, error
`messages, and real-time sensor data during operation of the
`jump starter 10. A reverse voltage LED 48 is illuminated
`when the microprocessor 12 determines that a reverse Voltage
`jumper cable Voltage is detected by reverse Voltage sensor 24.
`An auto mode LED 50 is illuminated when the automatic
`mode pushbutton 42 is depressed. A manual mode LED 52 is
`illuminated when the manual mode pushbutton 44 is
`depressed. If the voltage level of the jump starter batteries 22
`drop below a value of twenty percent of the normal level, a
`charge battery LED 54 is illuminated. The charge battery
`LED 54 remains illuminated until the batteries 22 are charged
`to a minimum state of charge Such as fifty percent, for
`example. A fault LED 56 is turned on anytime the micropro
`cessor 12 detects any operational, sensor or internal fault. An
`audible warning may also be provided 70. The fault LED 56
`remains illuminated until the fault condition is cleared.
`0021. A contact relay control output 58 operates the con
`tact relay 34 through temperature sensor 41. When the jump
`starter operation has been Successfully initiated, the contact
`relay 34 is closed and the jump starter capacitors 21 and
`batteries 22 are connected to the starter system or batteries of
`the vehicle to be started 28. The contact relay 34 is opened
`when a successful start cycle has been completed, a start fault
`has occurred or the operator interrupts the jump starter cycle.
`An optional keypad 72 may be included and used for entry of
`a passcode to operate the unit 10, or to identify one or more
`users of the system which may be stored to track user opera
`tion. For example, if two different users operate the unit 10
`and error conditions are recorded for one of the users, this
`information may be used to identify training issues that need
`to be addressed.
`(0022 Referring to FIGS. 2A, 2B, 2C, 2D and 3-8, when
`the jump starter 10 is initially powered on 200, the microcon
`troller 12 initializes the hardware, reads all system parameters
`and variables, and initializes the interrupt service routine 202
`(See FIG. 8). All stored performance history is read from the
`onboard, non-volatile memory 204 and a start message is
`displayed 206 on the LCD display 46. The history is saved for
`diagnostic, unit use and safety purposes. The microcontroller
`12 then performs a system self-test operation 208 where the
`LCD46, all LEDs 48,50, 52,54 and 56, all sensors 20, 24, 30,
`32, 38, 40, the push buttons 42 and 44, and the system bat
`teries 22 are tested and their status displayed 208 on the LCD
`46. If a fault is detected 400, an error message is displayed 402
`and system operation is halted.
`0023. Once the initialization and self-test operations are
`completed, the system starts into a main processing loop 210.
`An interrupt service routine (“ISR) 500 (FIG. 9) is also
`started which constantly monitors all input sensor values and
`user input buttons. The ISR 500 is periodically called by the
`microcontroller 502. A check is made to determine if the
`serial input buffer flag is set 504. If the flag is set 504, then
`configuration information is read and flags set or cleared 506.
`If the output flag is set 508, the information is transmitted to
`an external PC and the output buffer flag is cleared 510. Next,
`all input parameters are read 512, and a moving average is
`
`NOCO Ex. 1004
`Page 15
`
`

`

`US 2013/0154543 A1
`
`Jun. 20, 2013
`
`calculated for each parameter 514. If the PC remote flag is set
`516, all parameters and statuses are copied to the output
`buffer 518 and the output buffer flag is set 520. The manual
`mode AC starting current profile is calculated 522, all event
`timer counts are incremented 524, and the status of the auto
`matic 42 and manual 44 pushbuttons is monitored and set
`526. All calculations, timer counts, and status indications
`(flags) are stored in the internal memory of the microproces
`sor 12.
`0024. At the start of the main process loop 210, the flags
`are checked 404 beginning with the shunt calibration flag
`406. If the shunt calibration flag is set 406, the starter contact
`relay 34 is closed 408. The temperature of the shunt cable is
`measured 410 and the voltage drop across the shunt cable is
`read 412. The temperature of the shunt cable is measured a
`second time and averaged with the previous reading 414. The
`shunt resistance is then calculated and saved 416 and the
`shunt calibration flag is cleared 418.
`0025. Next, if the flag to upload data to an external PC is
`set 420, the information is copied to the output buffer 422, the
`output buffer ready flag is set 424, and the upload data flag is
`cleared 426. If the download data from PC flag is set 428, data
`is copied from the input buffer 430, and the download data
`flag is cleared 432.
`0026. If the PC remote control flag is set 434, the remote
`control status flag is toggled 436. If the flag is true, the unit 10
`can be controlled remotely by a PC or locally by the buttons.
`If the flag is false, the unit can only be controlled locally.
`0027. If the system does not detect a battery charging
`Voltage 212, once jumper cables 60 have been manually con
`nected to the vehicle to be started 28, the voltage is measured
`by the reverse voltage sensor 24 to determine if the cables
`have been properly connected to the vehicle 214. If the volt
`age measured is significantly less than the Voltage of the jump
`starter capacitors 21 and batteries 22, then a reverse polarity
`connection of the jumper cables to the vehicle is determined
`and an error flag is set and the event saved in non-volatile
`memory 216. A “Reverse Polarity’ error message is dis
`played 218 on the LCD46, and the reverse voltage LED 48 is
`illuminated 216. Any further jump starter action by the opera
`tor is ignored until the reverse polarity condition is corrected
`220, at which point processing returns to the start of the main
`processing loop 210.
`0028. If the jumper cables 60 are not reverse connected
`214, then the state of charge of the capacitors 21 and batteries
`22 is determined 222. If the voltage level of the system bat
`teries 22 measured by the voltage sensor 30 is equal to a state
`of charge of eighty percent or more below a fully charged
`voltage level 222, an error flag is set and the event recorded in
`memory 224. The charge battery LED 54 is illuminated and
`the LCD 46 displays a “Charge Battery' message 225. The
`system stays in this condition, which prohibits any further
`jump starter action by the operator until a charging Voltage is
`detected 226, which is great enough to indicate that a battery
`charger (not shown) has been connected to the batteries 22.
`0029. If the system has detected a battery charger voltage
`212, a “Battery Charging message is displayed 228 on the
`LCD 46, and the charge LED 54 is illuminated. The voltage
`profile of the battery 22 is monitored to determine if the
`charge is complete 230. A completed charge is determined by
`monitoring the charging Voltage rise to a threshold value then
`decrease by a predetermined percentage. This Voltage peak
`ing and Subsequent fall-off is a characteristic of the battery
`chemistry indicating that the battery has reached its maxi
`
`mum charge capacity. Once the charging has reached a mini
`mum charged level or is completed 230, the processing
`returns to the beginning of the main processing loop 210. The
`jump starter batteries 22 only need to reach a 50% charge in
`order for the system to attempt to start the vehicle.
`0030) If the battery or capacitor temperature measured by
`sensors 38 and 47 rises above a maximum safe threshold 232,
`an error flag is set and the event recorded in non-volatile
`memory 234. An error message “Battery Over Temperature'
`or “Capacitor Over Temperature' is displayed 236 on the
`LCD 46 and the Fault LED 56 is illuminated. The system
`prevents any further operation until the battery and/or capaci
`tor temperature falls below a safe level 238. Once a safe
`temperature is reached, processing returns to a ready state at
`the beginning of the main processing loop 210.
`0031. If the voltage of one or more of the capacitors mea
`sured by the capacitor voltage sensor 49 exceeds a predeter
`mined limit 239, such as 2.8 volts, for example, an error flag
`is set and the event recorded in non-volatile memory 241. An
`error message “Capacitor Over Voltage' is displayed 243 and
`the fault LED 56 is illuminated. Processing then returns to the
`main processing loop 210.
`0032. If the temperature of the shunt cable 36 rises above
`a safe threshold temperature 240, an error flag is set and the
`event recorded in memory 242. An error message “Cable over
`Temperature' is displayed 244 on the LCD 46 and the Fault
`LED 56 is illuminated. The system prevents any further
`operation until the shunt cable temperature falls below a
`minimum safe temperature 246. Once a safe temperature is
`reached, the system returns to a ready state at the beginning of
`the main processing loop 210.
`0033 Next, the system checks the status of the automatic
`42 and manual 44 push buttons. If neither button has been
`pushed 248, a “Ready' message is displayed 250 on the LCD
`46 and processing returns to the main processing loop 210.
`When no error conditions are detected and no user inputs are
`being processed, the system remains in the ready mode, and
`displays a “Ready text message on the LCD 46. Other infor
`mation Such as the selected jump starter Voltage, the percent
`age change of the batteries 22, the temperature of the batter
`ies, and the vehicle Vo

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